Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure

Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).


Note: The electrical system of the vehicle must be disabled to prevent operation of the wiper system while working in the vicinity of the wiper motor and linkages. Operation of the wiper system while working in the vicinity of the wiper motor and linkages may cause personal injury.

1. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).

Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Adding Fluid to the Brake System Caution (Adding Fluid to the Brake System Caution).

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).

2. Remove the knee bolster. Refer to Knee Bolster Replacement (Service and Repair).
3. Remove the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side (Service and Repair).
4. Remove the instrument panel retainer. Refer to Instrument Panel Retainer Replacement (Service and Repair).
5. Remove the power brake booster vacuum sensor from the vehicle if fitted. Refer to Power Brake Booster Vacuum Sensor Replacement (Service and Repair).
6. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
7. Remove the vacuum hose and check valve from the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement (6.0L) (Power Brake Booster Inlet Hose Replacement)Power Brake Booster Inlet Hose Replacement (3.6L) (Power Brake Booster Inlet Hose Replacement).




8. Remove the brake pedal pushrod retaining bolt (1), clip (2) and the brake pedal pushrod (3) from the brake pedal (4).




9. Remove the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Note: From the engine compartment, pull the vacuum brake booster forward to release the 4 studs from the bulkhead and brake pedal support bracket.

10. Remove the vacuum brake booster from the vehicle.

Installation Procedure

Caution: Refer to Adding Fluid to the Brake System Caution (Adding Fluid to the Brake System Caution).

1. With the aid of an assistant, install the vacuum brake booster from the engine compartment. Make sure the vacuum brake booster 4 studs are correctly located in the bulkhead and brake pedal support bracket.




2. Install the brake pedal push rod (3), clip (2) and brake pedal push rod retaining bolt (1) to the brake pedal (4).





Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the vacuum brake booster to brake pedal support bracket retaining nuts (1) and tighten to 23 Nm (17 lb ft).
4. Install the vacuum hose and check valve to the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement (6.0L) (Power Brake Booster Inlet Hose Replacement)Power Brake Booster Inlet Hose Replacement (3.6L) (Power Brake Booster Inlet Hose Replacement).
5. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
6. Install the power brake booster vacuum sensor from the vehicle if fitted. Refer to Power Brake Booster Vacuum Sensor Replacement (Service and Repair).
7. Bleed the braking system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).
8. Install the instrument panel retainer. Refer to Instrument Panel Retainer Replacement (Service and Repair).
9. Install the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side (Service and Repair).
10. Install the knee bolster. Refer to Knee Bolster Replacement (Service and Repair).
11. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).